The sealant between the two are the same...as for cutting. no one really shares their process on the vendor side of things. people usually heat and pry like mark mentioned.

on the contrary... i asked OSS directly and they confirmed they cut it open. I have a bunch of recordings on my process, if you give me a day, i will put together a video of what i did... i have some good tips on how to make a clean cut using a wheels. I plan on doing one too with using a router bit [2 flute solid carbide 1/32" bit]

Even though i had some hiccups along the way, it definitely was not because of the cutting process, but because i had shitty headlights to start off with. I've since then had plenty of practice on other peoples' headlights and i think i have it down pat now... ^__^

EDIT: And to add on to LUX's comment, i've tried the heatgun method, it doesn't work... the headlight lens will melt and bubble up before the glue gets soft/sticky in order to peel apart. I also tried heating up just the black housing part (directly behind the clear lens) and again, the housing gets soft and malleable before the glue does. If there's another method out there that someone KNOWS works, then please make a video of your process in order to not only prove me wrong, but to help the rest of use have a clean and professional project we can be ultimately proud of. ^__^

The reason the glue doesn't work like other headlights is because this (like the new GM/Chevy vehicles) headlight uses "Perma-Seal Gasket" it's an epoxy that resists heat below 500°, it's commonly used in making valve cover gaskets. Thus, why a heat gun has no effect.

on the contrary... i asked OSS directly and they confirmed they cut it open. I have a bunch of recordings on my process, if you give me a day, i will put together a video of what i did... i have some good tips on how to make a clean cut using a wheels. I plan on doing one too with using a router bit [2 flute solid carbide 1/32" bit]

Even though i had some hiccups along the way, it definitely was not because of the cutting process, but because i had shitty headlights to start off with. I've since then had plenty of practice on other peoples' headlights and i think i have it down pat now... ^__^

EDIT: And to add on to LUX's comment, i've tried the heatgun method, it doesn't work... the headlight lens will melt and bubble up before the glue gets soft/sticky in order to peel apart. I also tried heating up just the black housing part (directly behind the clear lens) and again, the housing gets soft and malleable before the glue does. If there's another method out there that someone KNOWS works, then please make a video of your process in order to not only prove me wrong, but to help the rest of use have a clean and professional project we can be ultimately proud of. ^__^

The reason the glue doesn't work like other headlights is because this (like the new GM/Chevy vehicles) headlight uses "Perma-Seal Gasket" it's an epoxy that resists heat below 500°, it's commonly used in making valve cover gaskets. Thus, why a heat gun has no effect.

I have opened up about 30 of these headlights since i used to the the CF wrap over the amber part. You need to set the heatgun to a fairly low temp so that the black plastic gets soft but not hot enough to burn or bubble the clear lens. After that you need to slowly pry the black plastic up so you can start breaking the seal on them. its not an easy process and its rather back breaking. You need to use a screw driver to break the seal and rip the glue apart that way

Gently heats up the plastic housing to allow space for a screwdriver to get underneath and brake the seal.

Quote:

Originally Posted by LuxAngelEyes

I have opened up about 30 of these headlights since i used to the the CF wrap over the amber part. You need to set the heatgun to a fairly low temp so that the black plastic gets soft but not hot enough to burn or bubble the clear lens. After that you need to slowly pry the black plastic up so you can start breaking the seal on them. its not an easy process and its rather back breaking. You need to use a screw driver to break the seal and rip the glue apart that way

10-4. I confirm what Mark says. I used a blow dryer instead of a heat gun. It was enough to get the job done. My housing is mint. Not even mangled a bit. I will send pics when I get to it. Cutting, is the quickest and easiest way I am sure. It was back breaking for sure to use this prying process but it will look and feel best in the end.

damn! O__O that's pretty clean! When i get a new set of lights, care to help me out with this?

Thanks. I have baby #2 about to come out of the oven any second. Let me know when you get another set and we can see how it works.

Quote:

Originally Posted by LuxAngelEyes

Now thats what i'm talking about!!! good job scraping all the old glue from everything.

Well, I used your guidance to get through it. I just refuse to take cutting to be the answer. I am awaiting my orion v4's so I can smack these babies back together again. The other side of the housing isn't as good as this one. I fudged it a little at the top because I didn't perfect the process. I think I have a pretty good handle on it now. I can't wait to do another set.

I'm trying to do a similar process on the X5 forums for my headlights, and agree that a blowdryer is much more controlled heat and less chance of mangling the plastic of the housing.

did you just use one small thin screwdriver, or a thicker one to get under and break the seal? I see a lot of the DIY's showing these big flat heads like a pry bar and all it does is mangle the housing, yours is CLEAN and any helpful tips would be appreciated!

Thanks. I have baby #2 about to come out of the oven any second. Let me know when you get another set and we can see how it works.

Well, I used your guidance to get through it. I just refuse to take cutting to be the answer. I am awaiting my orion v4's so I can smack these babies back together again. The other side of the housing isn't as good as this one. I fudged it a little at the top because I didn't perfect the process. I think I have a pretty good handle on it now. I can't wait to do another set.

details on the process you used? yours being opened is the cleanest job I've seen yet, which is why i'm interested on how you opened so cleanly. A detailed description along with tools used to pry (besides blowdryer) would be helpful, thanks

I just used a small flathead screwdriver to break the seal. I have a secret after that but I am holding on to it in case I decide to do these for others. Lastly, be very careful with the lens. As stated earlier, these are not cheap. If you damage the lens in any way, you need a whole new set.

I just used a small flathead screwdriver to break the seal. I have a secret after that but I am holding on to it in case I decide to do these for others. Lastly, be very careful with the lens. As stated earlier, these are not cheap. If you damage the lens in any way, you need a whole new set.

how did you get the projectors out? I've been at it for over an hr and it doesn't seem to fudge they are loose right now but i can't find what is holding on to them. Does it pop out?